Stitching Speed & Scale: How FIGS Built an Agile Supply Chain with DHL

In less than a decade, FIGS has transformed from trunk‑sales to a $750 million revenue brand, shipping roughly 16 million units annually. The company’s rapid ascent—driven by fashion‑forward medical apparel—creates a volatile demand pattern, with spikes during events like Nurses Week and Match Day. To sustain this growth, FIGS partnered with DHL Supply Chain in 2022, seeking a logistics provider that could scale alongside its expanding e‑commerce footprint while preserving the brand’s focus on healthcare professionals.

DHL answered with a bespoke zero‑walk automation system, often described as a gray‑orange robot fleet that lifts entire shelves and delivers them to stationary pickers. This technology slashes picker travel time, turning a labor‑intensive walk‑and‑pick model into a high‑throughput, low‑fatigue operation. By evaluating manual carts, Locus Robotics, and multiple robotic platforms, FIGS chose the solution that best matched its five‑to‑one peak‑to‑average volume ratio—30 k units daily average versus 150 k units at peak. The result is a flexible, labor‑light workflow that handles both high SKU variety and massive order spikes.

Beyond technology, the partnership thrives on cultural alignment and data‑driven collaboration. Both companies emphasize shared values, from employee well‑being to sustainability, ensuring smooth communication during rapid change. FIGS supplies DHL with detailed forecasts for promotional periods, enabling the 3PL to pre‑position inventory and fine‑tune robot schedules. This predictive accuracy reduces out‑of‑stock risk and accelerates delivery during critical weeks, reinforcing FIGS’ reputation for fast, reliable service to healthcare workers. As the brand continues to innovate in design and expand globally, the agile supply chain built with DHL positions it to meet future demand surges without compromising speed or quality.